Caution – S&S Cycle Bore 4 1⁄8 V-Series Engines User Manual

Page 11

4. Check rocker arm endplay by sliding rocker arm to one side

as far as possible and measuring gap between rocker arm
and support at opposite end. The specification for endplay is
.001”-.012”. If endplay is insufficient, carefully remove
material from end of rocker arm to achieve correct endplay.
Leave a smooth, non-abrasive surface finish.

5. Apply Loctite 243 to rocker arm support bolts. Insert two

⁄

-18 x 2

⁄

” socket head bolts and washers in left (drive)

side of support and two

⁄

-18 x 2

⁄

” hex head bolts in right

(cam) side of support.

6. Place rocker arm support assembly in rocker housing. Align

pushrod ends with sockets in rocker arms and tighten the
four support bolts to 18 ft-lbs.

7. Apply

Loctite

243 to the

⁄

-20 x 1” and

⁄

-20 x 2” socket

head screws. Install washers on both screws. Insert 1” screw
with washer in center left side of support, and 2” screw
with washer in center right side of support. Tighten both to
120 in-lbs.

8. The HL

T kit is installed in the lifters, and the pushrods must

be adjusted as follows:

a. Extend pushrod until it contacts the hydraulic piston

assembly in the lifter body, then extend pushrod an
additional four complete turns, until piston assembly is
in contact with HL

T spacer and the valve is lifted off of

it’s seat. If tappets contain oil, as when pushrods are
readjusted after engine has been run, or if all oil was not
removed during installation, allow at least 10 minutes
for piston assembly to bleed down.

b. Loosen pushrod adjustment until pushrod can be

rotated with the fingers with slight drag. Continue
loosening (shortening) pushrod one full turn (6 flats).

NOTE - Shortening adjuster an additional six flats or full turn
from zero lash often results in quieter pushrod operation. This
provides additional travel for the hydraulic piston assembly,
which can improve the ability of the hydraulic unit to maintain
zero lash under normal operating conditions.

Perform this operation on one cylinder at a time. Do not turn
engine until pushrod adjustment is complete.

Turning engine while valve is held off the seat could result in
valve to valve or valve to piston contact and serious valve
train damage.

Tighten lock nut.

Follow the same procedure for all four push rods.

NOTE - Upon initial start up after modification, HL

T equipped

lifters may be somewhat noisy for 10-20 miles.

9. Install upper rocker cover, gasket, and O-ring on rocker

housing.

10. Install one flat and one rubber washer on each of six

⁄

-20 x

⁄

” rocker cover screws. Tighten screws to 120 in-lbs.

11. Extend pushrod tubes and install pushrod cover

retainer clips.

12. Rotate flywheels until rear piston reaches TDC on

compression stroke (315 flywheel degrees past front piston
TDC) and both rear lifters are in lowest position on cam.
Repeat procedure for installing pushrods, rockers, and
covers, installing longer remaining pushrod in exhaust.

13. After pushrod adjustment completed per instructions, rotate

flywheels several revolutions in direction of normal flywheel
travel to confirm that engine turns freely.

NOTE - Do not force engine. If resistance encountered, determine
and correct cause before continuing.

Forcing engine against resistance may cause damage not
covered under warranty.

INSTALL INTAKE MANIFOLD
1.

Identify front and rear intake manifold flanges.

Apply a light coat of silicon lubricant, or Vaseline, to the
outside diameter of the manifold, the inside diameter of the
flanges, and the two intake seals. Install the flanges in
appropriate positions on manifold, smaller diameter
towards center of manifold.

Install seals onto manifold with the thicker end towards
cylinder head.

Install manifold assembly onto cylinder heads using the four
mounting screws. Snug screws finger-tight.

Install breather hose from front cylinder head to vent fitting
on top of carburetor intake manifold.

NOTE - Refer to engine installation section of this manual for
carburetor installation, throttle cable installation and
adjustment, and air cleaner assembly installation.

FINAL INSTALLATION
Finished engine should be installed in frame according to
appropriate Harley-Davidson

Service Manual. Clean gas and oil

tanks thoroughly before installing, and be sure all traces of
solvent are removed. Old oil lines should be flushed or replaced,
and a new oil filter installed. With engine installation complete,
carburetor and air cleaner assembly can be installed.

INSTALLATION

NOTE - The 4

⁄

" bore engine is designed to be installed in a stock

1984-’99 big twin chassis. If this engine is to replace an existing
engine, refer to the appropriate service manual regarding
engine removal.

Picture 26

CAUTION